Starter whine

[lugnut]

Some observations:

Bendix is the same , even for the Sportster.

I don't see a thrust washer(s) in any of your photos on the end of the jack shaft.
The shaft wants to travel towards the outer primary and the spline is sliding out of the reduction gear. These washers prevent this from happening. You should be able to assemble the primary with the gasket and reach up with 2 fingers and pull the shaft towards the jackshaft bearing in the primary cover. Mine had one washer and still alot of play. I put on a second washer and got it down to about .030 to .045" of end play.
PLEASE DISCONNECT THE BATTERY FIRST !

The bendix gear also looks too close to the ring gear on the clutch basket.
This can happen by installing the housing cover plate on backwards.The side with the O ring seal should be towards the reduction gear in the housing.

[greenbikemike]

They do have a bigger one, ZEN "Life-Time" 383-451 65-88 BT or sportster 67-80 you can see how much bigger it is around the bearing,but here it looks like the shaft isn't long enough or the spacer isn't right, like Hawg said,Just throwing ideas out there...

I don't know how to copy the exact page but its on page 247 after ya click the link,you can compare it to a stock one on the top of the same page...




http://www.jpcycles.com/catalog/2009...=05+Electrical

[ch47guy2008]

Thanks for the info on the different bendix/starter lever set ups, greenbikemike--I have to work late again tonight, so I won't be able to mess this this until Satuday a.m. I got a call from a local guy that's got a different starter and a stock starter housing--we're going to try that set up and see if that works. If it does, that means the POS aftermarket starter the PO gave me could be the problem. Will keep you folks posted. Bruce

[ch47guy2008]

Lugnut--yeah, I tried stacking thrust washers up on the shaft too. Total of three, made sure I still had some clearance in there too. (.025-.045) Or somewhere there abouts. Looking/working through the derby cover access was not easy. Going to tackle this issue again tomorrow a.m. Thanks, Bruce

[ch47guy2008]

Parts STILL not here...no deliveries due to the holiday....and I had to work this weekend! Crap. ch47guy

[venomous35]

im putting my outer cover back on and noticed no trust washer. dont know if it fell off or what. i have some washers that will fit on there that are a tiny bit bigger. does it matter much on the size and thickness as long as it fits without too much up and down play? or do i need one at all?

[BikerJim44]

The thrust washer is typically a brass washer that takes up the difference in the spacing. If you don't have the correct spacing and the thrist washer on there you can slam the shaft out to the outer primary and eventually it will crack or break it not to mention the shaft can have to much throw on it and you could end up tearing up the ring gear and starter gear not to mention everything behind it. Use the book and get the correct specs or you will be setting yourself up for trouble. If the washer is to big it will eventually wallow out and end up wadded up in there tearing up even more stuff. Just had one like that a while back. Spidey.

[HoustonCH73]

Ok CH47guy2008, where's an update? Ya can't leave us hangin like that.

[ch47guy2008]

Holy Crap! Sorry Guys....some of you know that I work two jobs out here, one of them being in the Nat'l Guard. Well, from time to time Uncle Sam calls us up and asks us to show him a return on his investment. This may include, but not be limited to, being sent to the mainland, (schools, training, etc.), and other (less) desirable places. That being said, I'll warrant the majority of you out there can guess what happened. Those of you that are vets will most assuredly understand, and can acknowledge my level of commitment to our country. I may be a bit of an old fart, but I'm fit, firm and 50, and one stubborn son of a bitch with a work ethic from hell. Haji better fucking look out. ch47guy